Apparatus for producing magnetic cores



May 31, 1932. K. SCOTT 1,860,843

APPARATUS FOR PRODUCING MAGNETIC CORES Original Filed March 6, 1929 2 Sheets-Sheet 1 v May 31, 1932. K. L. SCOTT 1,860,843

APPARATUS FOR PRODUCING MAGNETIC CORES Original Filed March 6, 1929 2 Sheets-Sheet 2 //7V6/77L0/ A. Z. S??? v I v y 427/.

Patented May 31, 1932 m A ES Q LFICE :KENivE'TH L: soo'rr, on WEsTERN srm ves, ILFINOIS, ssreNoR To wEsrERN, ELEC RIC i e COMPANY, mcoaroaa'rnn, or irnwyonmn. Y; a ooaronnrrouor unw 'Yon r arrnnnrus ronrnonuonm MAGNETIccoREs 1930. Serial I This invention relates to an apparatus for V producing magnetic cores, more particularly to an apparatus for producing magnetic cores of laminated conduction, and 1s a division of my co-pending application Serial No. 344,867, I

filed March 6, 1929.

Heretofore, in some instances, it :has been the practice in making ringers, induction coils and othertypes of telephonic apparatus employing electromagnets to use a solid core, or a laminated type of corecomposed of a number ofcomparativelythin strips of ma terial.:'

I Objects of the presentlinvention are to'proe vide. an apparatus-for manufacturing cores which will be economical, efficient andproduc'tive of a. one-piece type of laminated core possessing predetermined electrical and mechanical characteristics. V l In accordance with one embodiment-0f the invention, a sheet'of magnetic material is passed through a series of rollers havingcircumferential cooperating formingrbeads. and grooves "which progressively produce corrugations on the sheetoutwardlyirom the center thereof. The corrugation, produced by the first pair of-rollers determinesthe greatestcross-sectional dimensionof 'thefproduct, and the=depth of the corrugations produced by the remaining rollers determines'thecharacter of the cross-section of the product. The corrugated sheet is then passed through a sec- .ond series of rollers whichare driven-by a series of reducing gears,--meshing with the I rollers of the'first series, to feed'the material through the system at a constant speed. j The second series of rollerslcompresses the corrugated sheet edgewise to tightly closethe corrugations beginning with the innermost and produce in the resulting tone-piece typeof laminated core the predeterminedcross-section. Thereafter the core is heat treated to form oxide insulating coatings between adjacent surfaces of the laminations and to pro -'rluce the optimum magnetic characteristics.

the core. V It is believed that a complete understand"- ing of theinfvention may be securedby referringto the following description taken in conjunction awith, the accompanying drawwhich tional zview *Fig. 3is an enlarged rragmentary sectlonal I view takenon line 33 of Fig. 1;

Fig. lcis an enlarged fragmentary: sectional view taken on line 44:' of Fig. 3;

Fig. 5 is an enlarged corresponding sectional view takenonthe line 55 of Figr3; Figs-dis an enlarged correspondingsecd takenonathe lined-.6; ofF-ig. .3;

core. 7

qReferring to the drawings wherein ldentif cal: reference numbers indicate similar; parts on the several views, Fig. 1 "shoWs-aforming ence to thebase 11; V

In describing the. details (if-construction of the-apparatus, it will be necessary to ini-f Original application filed March 6, isaeyseriaruo. 344,867. "Divided and this application tied Marchlj,

so I

Fig. is a perspective view of a'completed elude" references to certain"featuresv or. the,

manner of its operation. It will bejob'served that raw or sheet materiallt is fed into a per ti o'n :of the apparatus corresponding tothe right-hand end of the: apparatus 10 shown inrFig. 1 ofthedrawings. In its operation, the apparatus a'cts to; move the material constantly to the left, from" which portion ofthe apparatus the completely. formed product is discharged a one-piece typewla'minated prismatic core '15.? Accordingly, wherewa number of similar elements engage the material insuccession they willbe individually distinguished byreierring to them in accordance with the order in which they engage re ai of fopp ositel'y disposed. guide plat s 16 are rigidly secured-to the sides 12 and 13 jofltheforming apparatus by screws 17', and

furnish a channel through which the mate-j rial let is fed'to a power roller18. The power roller islmounted-upon' a shaft" 19 suitably journaledso as to bepreadily rotatablev in the sides 1 2"and13f. The :power roller comprises is opposite a grooved roller of the'lower row,"

one of anseries of eighteen forming rollers,

the remaining units of which are mounted upon 1 rotatable horizontal shafts 21, journaled in the sides'12 and 18. The shaftslS) and 21 project beyond the side 13 a suflicient distance to permitmounting on the projecting portion of each a toothed gear 22.] The forming rollers 20 are arranged in parallel upper and lower rows of'ni'n'e rollers eacli'and are so positioned as to permit the gears Q-Qof the rollers in the upper row to, mesh with the. like gears of the rollers in the lower row.

. The series of forming rollers 20 include nine spaced beaded rollers and nine spaced grooved rollers respectively arranged in such manner, that a beaded roller of'the upper row @320, the upper one ofwhi ch is of the-beaded order and the lower of which is of the grooved order. T

The power roller 18 or the first beaded 011! or isprovided'with a centrally disposed circumferential V-shaped head 23 (Figs. land which coincides with and projects into a centrally disposedcircumferential V-shap'ed groove 24 with which the opposite roller-is provided. The head and groove fare .ofa

depth sufficientto form a longitudinal corrugation 26 (Fig. 4) in. the center ofthe sheet of magnetic material 14 whichhmayfbe in-- sorted and: passed'between them, whichcorrugation will be equal in depth to the greatest cross-sectional dimension of the core 15:(Fi'g".

7) to be produced. The second beaded roller is provided with two circumferentialqV- shaped beads 23 which project into two likeshaped grooves 24 with which-theopposite roller is. provided. The two beadsian'd: their respective cooperating groovesare spaced an equal. distance from center iof'tl ie rollersto form: in the sheet 14 aside wall. for two addi tional corrugations 27. and 28,.oneon either side of the lnltialcorrugatlon 26,.each' corrugation being of a depth silghtly less than the "depthof .the'. corrugation 26. The third beadedroller is provided with three beads,

which project into and cooperate'with three circumferential grooves of the third grooved roller. Thethree beads and *therespective grooves are centered with respect of therollers' and the beadf23 of the first roller; in order that the corrugations 27 "and 28"Inay' be imparted to the sheet duringits passage between the third "pair ofi-oners '20, aims; completing the corrugations commenced by the 'second four grooves of the fourth grooved roller. The four heads and the cooperatinggrooves are spaced an equal distance from center, the

side wall fortwo additional corrugations 29 and 31, one on either side of the. prior-formed corrugationsand each to be of ad'epth slightpair'of'rollers. The fourth beaded roller is provided with four beads which project into 7 .two outermostacting to form in the sheet a ly less than the depth of the corrugations 27 a j and 28. The fifth beadedroller is provided with fivebeads which project into five grooves of the 'fi'fth grooved roller.v The 'five beads and cooperating groovesare "centerediwith respect of the .rollers in order that the corru'gati'ons 2'9 and 31 may be coinpletedin the sheet 1 1 durirrgits passage betweenthe fifth 1 pair of rollers. The sixth and seventh,ian d eighth and ninth pairs of rollers are respec tively provided with twoaa-dditional 'beads and grooves to im-pressu'pon the sheet. two i addition-a1 corrugations .respectivel:y,';' sixth and seventh corrugations 32 and 33 being-of a depth proportionalto: the depth of'the initial corrugation 2.6 in a ratio higherthatn that ot the prior corrugations; and eighth and ninth corrugations 34 and 46 being of a depth V proportionalto the depth ofthe initial corratio of approximately. one to three... I

DllgFEttlOTla in Rotatably mounted in the sides upon shafts 31 are a" series of eight idler gears 38,'so located with respect to .the forming rollers 20 2.5 :to eaclr mesh with the gears 22 of two adjacent pairs oflowerrollers; and to communicate :themotion derived fro m one of said rollersto the other.v In such manner 7,

the: rotation. impressed upon thepower rolh er'18' by any suitable driving mechanism (not shown.) isconimunicated to-each rjoller of the series, to theend that-:theymay be driven at the-same rate of speed. A'series of eighteen guard plates 39', ri-gidlysecured to the sides 12 and 13 by screws flare positioned onetothe immediate left of each roller so that a curved f-ace- 42' of a. guard-plate. 39' is. closely aligned with the curved surface; of a roller.

'Each guard plate 39 iss-haped. to closely foll lowthe contour ofthe roller with'which it; is associatedg to the extent that-those ass ociated with grooved rollers have -V-shaped" projections; which conform; with the grooves of therol-ler and those associated'withbeaded rollers have V shaped notches toreceive the beadsthereon The guards are-arranged in 7 upper. and lower-rows which arespaced-suf formed.

A: pressingapparatus, generally denotedby ficiently apart to permit the? materialtopass hetweenthemin ahorizontal-path,.the'curved faces 42. acting to prevent the" material. 14' a from bending around a roller 20' as itisbeing' the. numeral? 43, inclu'desa base 44; sides-:45

and 46,. a top-47and an endportion Roof the pressing apparatus-and 's uitably journaled therein on shafts49 so as to be freely rotatable in a series of four pairs of oppo;

sitely disposed pressing rollers 50','each roller having a centrally located groove 51 extending aboutthe'periphery of'the rollers in the same horizontal plane with the' corrugating members 23 and :24 of the forming rollers The depth ofthje-grooves 51 of the first pair of pressing rollers 50 is suchthat an opening between therollers is presented WlllGllWlll be of a width'proportional to the width of the corrugated sheet discharger from. the ninth pair of forming rollers in the ratio of approximately three to four. The grooves of the second pair-ofpressing rollers present an opening of a width proportional to the width of the Corrugated sheet'at the same stage in the ratio of approximately. one to two, The grooves of the thirdpai'r present an opening proportional thereto in the ratio of approximately one to four. The grooves of the fourth and last pair of pressing rollers 51 present an opening of a width proportionalto thewidth of thecorrugated sheet in a ratioof approximately one to eightythe exact size o fithe rooves of the last 'pair of pressing rollers ultimate cross-section and diameter which it is desired the finished core 15 to'posses's. The contour oftliezgrooves of the first pair of rollers is such'that the walls of each. abuttand closely engage the exterior edges of'the corrugations for approximately of the depth 7 of each groove, to the end'that the resulting compression of the material shall. occur initially. at the centermost corrugations, as

shown in'Figi3, .thus insuring that the deeper and more resilient laminations occuring at i the center of the sheetshall be compressed beyond-the elastic limitand given a permanent set. Accordinglyflthe walls of the grooves of the second pair. of rollers abut and closely engage the exterioriedgesof'the corrugation for. approximately 5%; of the depth of agroove, and the :walls of the grooves of the third pair of rollers similarly engage the edges. for approximately 5; of the depth of agroove, the resultant tendency being to render the horizontal compressing 1 force of the rollers effective only at the center ofthe material. The grooves of the last pair j of rollers are hemispherical and act .to :com-

" press the remaining corrugations and impart to the material its final predetermined cross-section vThe press rollers 50 receive the corrugatedsheet from thelast pair of forming rollers and forward itthrough the grooves :51 in a constantly horizontal path from right to .leftto progressively decrease its width in accordance with the approxi mate ratios 'stated.- Stationary guide'and compressing members 52 spaced'between the compressing "rollers assist in' defiectiiig the eing determined by the sheet as it passes from a r'espective-roller, to

guide the edgesof thematerialas-itf is passed.

into the 'subsequentrollerl Thelast' pair of pressing rollers 50 forward the-completely formed one-piece laininatedi prismaticacore l5sth'rough a discharge "chute 153'awhic'h acts to load the cores 15 into a {suitableltype of annealing boX: (not. shown) "for. heat treat? ment;v I a Although the :fo'reg oing deals; with the treatment of short lengths of sheet ma= terial which have been cut to determine the length ofthe. completedcore, zit shouldbe apparent ithat the inventionis capabler of similarly treating" material 'comingi con tinuous lengths should .suchwbe i'founde; more convenientzoneconomical;; J

5 The'inain'id-lergear-5Qiskeyed' to lai '55 rotatably mountedin gthe-vsi'de l3g of 'a forming apparatus so asato mesh 'with the last gear 22 ofthe forming apparatus. :Aj'series 1 of four gears 5(iis provided exteriorly of the side'45 mounted on horizontal shaftsbt'which are rotatablyj-ournaled insides-and 46 of I (I thepressing apparatus.-. Theffirsflgear 56 meshes with themain idlerwgearb l and acts to rotate the shafts 57gaiMountediinteriorly ofthe sides45 and'ii-on theshafts 5'Zso as to rotate: therewith is a seniesof eight driven gears 58 arranged in pairs which :meshzwith alseries'of eightrbeveled gears-59 arranged i in pairs and suitably keyed-to the shafts 4:9 of

the pressing rollers '50 so ast o cause rbtation of 'the rollers in accordance therewith. A series of three minor i-dlerigears .61 rotatably mountedon pins,.62 mounted in the-side 4'5 are'individually spaced to connect thegears 56 with' each OthGIYnIlA. cooperationflisthus."

established between the ,vari'ousseries :of

gears in such manner that'the mainidler 1 gear 5a [rotates the, first gear 56 of the pressing apparatus in accordance with "the rotation of the last gear 22' of the forming apparatus. I

The gear 56 rotates thefirs't shaft 57 .150 drive the first pair of drivengears; 58. Thedriven to reduce the speedof'frrevolutionp of;the

Ypressingrollers to corifespond'lwitlithe de creaseintdepth ofthe groove 51 SL 11lfOllIldlng the rollers in such manner that the "the fmatei'ial is forwarded through thel'pressing system at a constantsp'e'ed regardless ofthe grooves 51 constantly decreasing depthofthe isuccessive 4 a From the foregoing "it" j'bef observed that a sheet of material 14L inserted between guide plateslfi andifed into'thefOrming rollers 20, isgripped by-the first pair of forming rollers andmoned to the left. The-form:-

ingbead123 impresses thereon -by reasonof d3? engagementwitlr the groove of the op:-

ers it'has been longitudinally corrugated at' spaced points throughout its entire width,

' presentingan appearance as shown? in Fig. 4.

v 1 the materialisied readily from roller to roll- 20 into thec ent'ral grooves '51 ofthe pressing v lVh'en' vthe material emerges from In passing between the forming rOIlersQO,

any; tendency of the material to: curl or to de fleet, from its: horizontal course is-vovercome by -the guard plates 39 in such manner that er the series without choking or rumpling.

'U v enieging'fronrbetween'the final pair d rollers theisheet' passes'between the last guard plates and is forced'by therotation and feeding action of the 'final forming rollers rollersfiO The pressing rollers, in respective pairs,- rot'a-t-e' oppositely toyeach other to forward the material to-the'left, and each pair cooperate in succession to press the outermost. corrugations inwardly upon the center,

through the agency of the grooves 51; t e femur pairofipressing rollers at the extreme left of the apparatus, it will be ,i'ou-nd to shaped, as showninlFig; 7 0i the drawings, as a prismatic core of circular crossesection, It should be understoodthat a coreof any other OIOSS-SGCtIOH' may be produced by suitably altering"the relative size and positionsoi the beads and grooves on the forming rollers and the" contour of the grooveson'the pressingrollers, For instance, to form a core of rectangular cross-section,

' all of the beads on the forming rollers-should of -the"sarne height and equallyspaced to produce in the materialspaced corrugations of a uniform depth', andthe sheet so corru-' gateds-hould be subjected to pressing rollers having' 'grooves of substantially rectangular cross-section; u

v i In accordance with the above description, magnetic core will be: produced which will fQ-undjto possess the maxima; of desirable mechanical and; magnetic characteristics, in

that its one piece' or unitary condition causes it to be stronger, more rugged, and more easilyhandled than hitherto known types of j laminated cores. The'core itseli is readily assembled without intermediate handling, and the fact that, though laminated it is essentially; a unitary article enables it to be readily machined to receive threaded screws forthe': supporter attachment of other objects, orv for itsconnection to other partsand apparatus, thus obviating many of the. difrficulties -which have hitherto been en'- counterediin handlinglaminated c'oresiof the old. loose-leaftype.

It should be understood that althoughthis invention has been described in connection with on'etypeoi apparatus, the invention obviously lends itself to many other forms of machining apparatus having 'a number of rollers capable oftransforming sheet materi'al into unitary cores having numerous integral laminations tightly pressed together without departing from the spiritand scope j of this invention,and the invention therefore should be limited only by the scope of the" appended claims; 5

In; an apparatusfor: producing mageso I netic cores, a plurality of forming rollersior producing a, pl-ur'alityof corrugations in ,a

sheet of magnetic'material, and arplurality 0t pressing-rollers associated therewith for causing opposite; walls of the corrugations to closely. abut having grooves for grippingexr terior: edges of certain corrugations'to render the pressing force eiiective on the remaining corrugations.

'2. In an apparatus fori-producing magof magneticVmaterialspaced corrugations of a Width topredetermine the ultimate cross-V sectional character of the core, and vmeans for tightly compressingthe sheet to form the material into a prism having a. predeterminedcross-sectional characten;

3. In an apparatus torrproducingmag- .netic cores, a plurality of forming rollers including a'positively driven roller for producing a plurality of corrugationszina sheet; r i

of magnetic material, aipluralityof gears '90 nietic cores,1neans for producing in asheet connected to the forming rollers, and a plural ity of, pressing rollers associated there with for'graduallycompressing the material to cause oppositewalls'of the, corrugations 'to abut and form a compact core. 1

4. In an apparatus for producing magnetic cores, means for 'compressing'asheet of corrugated material, said means comprising a pair of rollers having annular .grooves arranged to receive an end ofithe corrugated material aIId'QGI IlPIQSS; the material lateral+ 1y during movement thereofbetweeni said rollers for form ngthe material into a-compactrcore."

p 5;. In an apparatuswfor producing mag-f net1c1cores, means forgcompressing a sheet r of corrugated material to cause the Walls of;

the corrugations. t'o' abut for forming a compact core, said means comprising a pair of rollers having annular grooves arrangedto receive an end of theicorru'gated material and-compress the materialduring movement thereof between said jrollers, anda second set of rollers having grooves therein arranged to receive: the corrugated material, for further compressingthematerial asthe material is passed therehetweeni;

. l n ppa at s or .P lui l gAn s anetic cores, means for compressing a'sheet as the material is passed between said second J i set of rollers, and stationary compressing members disposed between said sets of rollers for compressing the material as it is passed from said first set of rollers to said second set of rollers.

7. In an apparatus for producing magnetic cores, means for producing in a sheet of material spaced corrugations decreasing in size from the center outwardly, and means for compressing the sheet laterally to cause the walls of the corrugations to closely abut for forming a compact core substantially circular in cross section. v

8. In an apparatus for producing magnetic cores, means for compressing a sheet of corrugated material including means for first compressing certain of the corrugations without changing the remaining corrugations, and means for thereafter compressing the remaining corrugations for causing the walls of the corrugations to closely abut.

In witness whereof, I hereunto subscribe my name this 22nd day ofFebruary, A. D.

KENNETH L. soo'r'r. 

